Spinneret device for spinning side-by-side type of composite fibers



1967 MASATOSHI YOSHIDA ET AL 3,350,741

SPINNERET DEVICE FOR SPINNING SlDE-BY-SIDE TYPE OF COMPOSITE FIBERS Filed April 18, 1966 3 heets-Sheet .1

7, 1967 MASATOSHI YOSHIDA ET AL 3, 0,

SPINNERET DEVICE FOR SPINNING SIDE-BY-SIDE TYPE OF COMPOSITE FIBERS Filed April 18, 1966 s Sheets-Sheet :1

FIG. 9

Nov. 7, 1967 MASATOSHI YOSHIDA ET AL 3,350,741 SPINNERET DEVICE FOR SPINNING SIDEBYSIDE TYPE OF COMPOSITE FIBERS Filed April 18, 1966 s sheets-sheet s 6 638 FIG. 5

73 w A B C D E F J T" llll lllll FED BA '7 W1 United States Patent C 3,350,741 SPINNERET DEVICE FOR SPINNING SIDE-BY- SIDE TYPE OF COMPOSITE FIBERS Masatoshi Yoshida, Kamitokari, Sunta-gun, and Keisuke Tanouchi, Mishima, Japan, assignors to Toho Beslon Kabushilri Kaisha, Chuo-ku, Tokyo, Japan, a corporation of Japan Filed Apr. 18, 1966, Ser. No. 543,204 Claims priority, application Japan, Apr. 22, 1965, 40/23,806 7 Claims. (Cl. 18-8) ABSTRACT OF THE DISCLOSURE A spinneret device having a distribution block comprising three adjacent disc members between an introduction block and orifice block, whereby improved conjugatability, uniformity of distribution and simple construction result.

This invention relates to a spinneret device for spinning side-by-side type of composite fibers, and more particularly to such a spinneret device of which construction is relatively simple and yet which is capable of spinning the conjugated fibers with high efficiency and with a high degree of uniformity in component distribution as between individual fibers.

Heretofore various composite or conjugated synthetic fibers have been in public knowledge and use. They are formed by spinning two sorts of polymer dope in such a way that each of the components is combined to form a single fiber or filament in cross-section, of which every component occupies respective zone. Depending on the manner of distribution of such zones in the fiber crosssection, the conjugated fibers are classified into side-byside type, sheath core type and the like. When two types of polymers having diiferent shrinkage characteristics are formed into side-by-side type composite fibers, they develop crimp by after-treating under such conditions which cause the two components to respectively undergo different shrinkage.

In order to make up such side-by-side composite fibers, various constructions of spinneret devices have been proposed, in which it is basically necessary to direct two spinnable dopes from two inlets to each of a plurality of spinneret orifices. However, these devices have been proved quite unsatisfactory in view of the lack of uniformity in component distribution as between individual fibers; or of complexity of the construction and resulting higher cost in manufacture; or of lower spinning efiiciency due to limitation in the number of orifices provided in a given area of the single spinneret.

It is thus a principal and fundamental object of this invention to provide an improved spinneret device for producing side-by-side composite fibers whereby the faults as referred to above may be avoided and overcome.

This object and other objects as well as attendant advantages which will be apparent from the following disclosure are attained by providing a device comprising an introduction block having first and second longitudinal passages for supplying respectively first and second spinning dopes, an orifice block having a plurality of spinneret orifices arranged along a plurality of concentric circumferences coupled by a means for mechanically connecting said introduction block with said orifice block so as to provide therebetween a space for housing a distribution block. Said distribution block comprising a first disk member having two groups of passages formed therein so as to distribute said two sorts of dopes separately in radial direction, a second disk member having p ce a number of holes and a third disk member having a plurality of concentric annular grooves respectively formed in the upper and under surfaces thereof. Said upper grooves and correspondingly located lower grooves being respectively connected by a plurality of perforations formed at regular intervals, whereby the two sorts of dopes alternate in concentric circular falls at said lower grooves so as to extrude into a coagulating bath to form side-by-side composite fibers through said spinneret orifices, which are arranged so as to face close to respective concentric annular partitions between said lower circular grooves.

By combining said three distributor disk members, two sorts of dopes can be distributed uniformly both in radial and circumferential directions and the number of spinneret orifices can be increased in a given area of the spinneret device. Thus the essential advantage of the present invention is to concurrently obtain uniformality of the product and increase of the productivity.

A preferred embodiment of the present invention is illustrated not exclusively but merely for the purpose of having same understood better in reference to the accompanying drawings, in which:

FIG. 1 is a longitudinal section of the spinneret device in assembly according to the present invention,

FIG. 1A is a similar view wherein four blocks constituting the assembly are shown in decomposed status,

FIG. 2 is a top plan of the first disk member of the distributing block wherein under surface recesses are shown in phantom,

FIG. 3 is a longitudinal section of the first disk member of FIG. 2 taken along line III-III,

FIG. 4 is top plan of the second disk member of the distributing block, wherein the locating of the perforations are illustrated by broken lines,

FIG. 5 is a longitudinal section of the second disk member of FIG. 4 taken along line V-V,

FIG. 6 is a longitudinal section of the third disk member of the distribution block,

FIG. 7 is a top plan view of the third disk member of FIG. 6 taken along line VILVII,

FIG. 8 is a bottom plan view of the member of FIG. 6 taken along line VIILVIII, and

FIG. 9 is an enlarged schematic sectional view showing arrangement of spinneret orifices, partitions and under face annular grooves as well as one embodiment of the shape of the end of the protruding partitions.

Referring now more particularly to the drawings, a preferred embodiment of the spinneret device according to this invention is shown as generally represented by a numeral 10 in the assembled sectional view of FIG. 1. The assembly 10 basically comprises, as seen best in the decomposed sectional view of FIG. 1A, an introduction block 11, an orifice block 12, a coupling block 13 and a distribution block as generally represented by a numeral 14.

The introduction block 11 has longitudinally or axially extended passages 20 and 21 respectively for supplying the first and second spinning dopes to the distribution block 14. The passage 20 leads to an annular recess 22 and passage 21 leads to a central recess 23. Said recesses being provided respectively at the bottom end surface of the introduction block.

Two sorts of spinning dope are supplied via distribution block 14 to spinneret orifices 30 formed in the bottom wall of the nozzle member or orifice block 12. The spinneret orifices 30 are preferably arranged along a plurality of concentric circles respectively at regular intevals as hereinafter illustrated in more detail.

The introduction block 11 and the orifice block 12 may be coupled by any suitable means. In the present embodiment, coupling block 13 has an inner thread 40 adapted to engage with an outer thread 24 formed around the introduction block 11 and an inwardly projecting flange of which upper shoulder 41 abuts against an outwardly projecting flange 31 of the orifice block 12.

The space formed between the under surface of the introduction block 11 and the upper surface of the orifice block 12, retains the distribution block 14 which consists of a first disk member 50, a second disk member 60 and a third member 70.

As shown in FIGS. 2 and 3, an upwardly projecting boss 51 on the first disk member 50 with central opening 52 so that said openings 52 extends the passage 21. A plurality (six in the present embodiment) of radially extended recesses 53 are provided in the under surface of the first-disk member 50 so that inner end of each of the radial recesses 53 opens into the central opening 52. A similar number of radially extended openings 54 are alternately arranged between recesses 53 and communicate the annular recess 22 of the introduction block 11 as shown in FIG. 1.

A plurality of groups of perforations 63 and 64 are found in the second disk 60. The first set of perforations 633, D and F are arranged so as to lie within an area communicating with the radial recess 53 of the first disk member and the second set of perforations 64A, C and E within an area communicating with the radially extended opening 54. It will be seen from FIG. 5 that these perforations are arranged along a plurality of six concentric circumferences in the embodiment illustrated. These six groups of perforations are designated centripetally 64A, 63B, 64C, 63D, 64E and 63F, as seen in FIGS. 4 and 5. It will be appreciated therefrom that the innermost circle perforations 63F belong only to the first set of groups, the second circle perforations 64E to the second set of groups, the third circle ones 63D to the first set of groups and so on.

There are six concentric annular grooves 71A, 71B, 71C, 71D, 71B and 71F in the upper side of the third disk member 70, each of which are arranged respectively in alignment with perforations 64A, 63B, 64C, 63D, 64B and 63F. Correspondingly, there are six concentric annular grooves 72A, 72B, 72C, 72D, 72E and 72F in the bottom side of the third disk member 70. Six groups of perforations 73A, 76B, 73C, 73D, 73E and 73F in said third disk member 70 are arranged at regular intervals to open into the corresponding upper and lower annular grooves 71 and 72. The third disk member 70 has a flange 75 which abuts the flange 31 of the orifice disk member 12 which in turn, abuts shoulder 41 of the inwardly projecting flange of the coupling member 13, when the device is assembled.

In FIGS. 6 and 8 it will be noted that the lower annular grooves 72 are divided by respective annular ribs or protruded partitions 74.

The spinneret orifices 30 in five concentric circles of the orifice block 12 are arranged such that every orifice circle is in alignment with a median circle of the respective annular rib 74. The inner surface of the orifice block 12 are spaced from the rib surface when the device is assembled as seen in FIG. 1. The rib face is preferably concaved, as illustrated on a larger scale in FIG. 9. The cross-sectional configuration of the end of rib 74 is preferably shaped as an inverted V, inverted W, inverted U or the like.

When two sorts of dope I and II are fed to the spinneret device of the present invention for forming side-byside composite fibers, the flowing paths are as follows. The dope I is supplied from the reservoir (not shown) under pressure through a gear pump (not shown) to the longitudinal passage 20. The dope I then enters the annular recess 22; flows therefrom through the radially extended openings 54 in the first distribution disk to the perforations 64A, 64C, and 64E in the second distribution disk into the upper annular grooves 71A; 71C and 71B in the third distribution disk, and through the respective perforations 73 to arrive at the lower annular grooves 72A, 72C and 72B. The second dope H is fed into the longitudinal passage 21 in the introduction block 11 and flows through the central opening 52; the radially extended recesses 53 in the first distribution disk; then the perforations 63B, 63D and 63F in the second distribution disk, and then the corresponding perforations 73 to arrive at the lower annular grooves 72B, 72D and 72F in the third distribution disk. The dopes I and II proceed to the orifice block 12 and are distributed in the form of six circular curtains which are extruded through the orifices 30 respectively arranged with facing at the partitions 74 whereby side-by-side composite fibers may be formed.

The objects and advantages of the present invention can be attained by the construction and arrangement of the spinneret device as referred to above but it has been found that when the following matters are taken into consideration the superior results can be obtained.

In order to attain one of the objects of this invention, which is to improve the productivity per unit of spinneret device, it will be necessary to increase the number of spinneret orifices in a given area as far as possible by decreasing the interval between adjacent annular grooves in the third disk member. However, it has been also found that when the widths of the partition and of the groove are to be made too narrow the smooth flowing of dope is apt to be obstructed and undesirable conjugation of two components and lack uniformity of the resulting composite fibers result from a slight difference or function or change in various conditions, such as, change of dope viscosity caused by differential temperatures between the central and peripheral portions of the spinneret device; difference of resistance to free flowing 0f the dope in various passages of the distributor disk members; deviation from the alignment of the partitions with correspondingly located orifices caused when the device is manufactured or assembled, and the like.

The inventors have found that the dimensions and location of the perforations formed in the third disk member prevent the faults as referred to above and also help obtain other desirable properties of composite fibers. The relation of the number of perforations formed along the concentric annular groove in the third disk member and that of the spinneret orifices arranged along the corresponding circumference is to be represented by equations:

wherein Di: Number of perforations formed along the innermost annular groove,

D0: Number of perforations formed along the outermost annular groove,

Dm: Number of perforations formed along the No. m concentric annular groove counting from the innermost groove,

Ni: Number of orifices formed along the innermost circumference,

No: Number of orifices formed along the outermost circumference,

Nm: Number of orifices formed along the No. m concentric circumference counting from the innermost circumference,

k: Constant, and

V: Coefficient ranging 0.8 to 1.2, and more preferably Dm=k wherein Rm: Diameter of perforations of No. In annular groove, Dm: 'As defined above,

k: Constant, and

a: Coefiicient ranging 3.6 to 4.2 and more preferably In order to minimize the difference of resistance caused by various passages inthe distribution block, when the dope passing from the central recess 23 through the radial recesses 53 to the innermost circle perforations 63F, third circle perforations 63D and fifth circle perforations 63B,'it is preferable to determine the dimension of perforation so that the total amount of output fluid from perforations in the innermost annular groove and in the annular groovethird from the innermost one. in the second member and/or in the third member may be respectively 20-60% and 60-100% of the total amount of output fluid from the other perforations.

When it is necessary to have the thickness of the pe riphery portion of the'distributor disk larger than that of the center portion, the diameter of the perforations in the thicker disk portion will have to be correspondingly increased since the distance traveled through the perforations is longer and inevitably causes an increased re- 'sistance to the dope flowing through these perforations.

The relationship between the length d and the diameter Rof the perforation is expressed by the following equation:

R.=k"d(0.8-1.2) (3) wherein k means a constant. 7

In solving the problem caused by deviation from the alignment of the rib or protruded partition with correspondingly located orifice, it has been found preferable to provide the extremity end of the partition with a concave notch or recess as shown in FIG. 9 whereby faults are substantially prevented thereby substantially reducing delays during actual production. When the distance between the partition and spinneret orifice is considerably large, the spinning dope will not be uniformly delivered to the concentric annular groove from the outlet of the sure is varied accordingly; conversely, when the distance is too close the free fiow of dope is unduly hindered by the resistance thereof and it is difficult to maintain uniformity of conjugation. According to this preferable feature of the invention, not only is the fiow of dope through this zone stabilized, but also the ability of the two componeuts to conjugate as side-by-side fibers is considerably improved.

As referred to above, the present invention may be practiced in several embodiments, but it is preferable that the distance between the contiguous partitions or the width of the concentric annular groove of the third disk member be 1-3 mm.; the distance between the adjacent annular grooves or the width of the partition be 1-3 mm.; and the distance between the notched end of the partition and spinneret orifice plane be 0.150.5

The spinneret device according this invention may be used for wet-spinning, dry-spinning and fusing-spinning to produce composite fibers and especially side-by-side fibers formed by wet-spinning acrylonitrile polymer.

The following is presented to further explain the various features and advantages of the present invention.

One dope to be spun into side by-side composite fibers from an aqueous solution of the polymer and zinc chloride containing 9.0% polymer by weight was prepared by polymerizing a mixture of 90.5 weight percent acrylonit-rile and 9.5 weight percent methyl acrylate at 45 C. using ammonium persulfate as an initiator in a solution consisting of weight percent zinc chloride, 3 weight percent sodium chloride, 1 weight percent acetic acid and balance water. The viscosity of the resulting polymer solution was 102 seconds measured as the time during which a 130 mg. steel ball falls 20 cm. in said solution at 45 C. The other dope was a similarly prepared 9.0% polymer weight by solution consisting of a polymer of 88.5 weight percent acrylonitrile and 9.5 weight percent methyl acrylate and 2.0 weight percent sodium allylsulfonate. The viscosity was 98 seconds as determined by the method set forth above.

These two dopes were heated to 40 C. and supplied through two gear wheel pumps to the spinneretdevice of the present invention (see the following table) respectively at a rate of 200 col/minute. The device was provided with a nozzle or spinneret orifice block having 4,500 0.12 mm. diameter orifices. The dopes were extruded into the coagulating bath consisting of an aqueous solution of 29 weight percent zinc chloride at a temperature of 15 C., and then treated in a convenperforation of the disk member unless the extruding pres- 50 tional manner to obtain side-by-side composite fibers.

TABLE (DATA OF SPINNERET DEVICE USED) 2d Disk 3d Disk Orifice Block Interval Circle Or Between Annular Diameter of Adjacent Diameter of Diameter of Groove N 0. Number of Perforation Number of Perforations Concentric Concentric Number of Concentric Perforation (mm.) Perforation AAlonlg Circle (mm.) Circle No. Perforations Circle (mm.)

nnu ar Grooves (mm.)

1 Innermost.

In this case six (6) radially extended ogenings and six (6) radially extended recesses are provided in the first disk, and consequently the perforations in the second and thir disk are formed respectively in twelve (12) concentric circles and annular grooves. The

diameters of perforations in the second disk and of orifices are respectively of 1.2 mm. and 0.12 mm. Every interval between adjacent orifice circulars is 0.46 mm.

B-A B was 18%, wherein A represents the length of the crimped fiber imparted with initial load of 2 mmg./ den. while B represents that imparted with 50 mmg./den. load.

This invention'has been disclosed in a preferred embodiment, but it shouldbe noted that various variations and modifications may be made by those skilled in the art as occasion demands without parting from the spirit and scope of the invention as set forth in the following claims.

What we claim:

1. In a spinneret device for use in spinning a plurality of side-by-side composite fibers, the combination including an introduction block having first and second longitudinal passages for supplying respectively first and second spinning dopes,

an annular recess in the surface of said introduction block communicating with the second longitudinal passage,

a distribution block adjacent said introduction block comprising a first disc member having means defining a central opening communicating with the first longitudinal passage,

a plurality of radially extended recesses in the under surface of said first disc member, each of said radially extended recesses communicating with said means defining a central opening so as to distribute said first spinning dope in a radial direction,

means defining a plurality of radially extended openings in said first disc member arranged alternately between said recesses and communicating with said annular recess,

a second disc member having a plurality of perforations being arranged along a plurality of concentric circumferences such that perforations along alternate concentric circumferences communicate with said means defining radially extended openings while the perforations along the other concentric circumferences communicate with said radially extended recesses,

a third disc member having a plurality of concentric annular grooves correspondingly located in the upper and lower surfaces thereof,

means connecting said grooves in the upper surface with correspondingly located grooves in the lower surface,

said concentric annular grooves being arranged to communicate with the perforations along the corresponding concentric circumferences of said second disc,

concentric annular partition means between adjacent grooves in the lower surface of said third disc member,

an orifice block being adjacent to said third disc, said orifice block having a plurality of spinneret orifices arranged along concentric circumferences adjacent said partition means, said orifices being in communication with and intermediate to adjacent concentric annular grooves whereby said first and second dopes appear in concentric annular falls alternately at said grooves in the lower surface and are extruded from the spinneret orifices intermediate said grooves as side-by-side composite fibers.

2. A spinneret device as set forth in claim 1 further including, a coupling means having a substantially cylindrical member, said cylindrical member having one end adapted to engage said introduction block and an inwardly projecting flange at the other end thereof so that said flange abuts with said orifice block which said third disk member which abuts with said second disk member, which abuts with said first disk member, whereby when assembled said distribution block is sealingly housed by said introduction block orifice block and cylindrical member sealingly connecting passages leading from said first longitudinal passage to each of said alternate concentric annular grooves in the lower surface of the third disk member and from said second longitudinal passage to each of said other concentric annular grooves in the lower surface of the third disk member.

3. A spinneret device as set forth in claim 1, wherein the means connecting said grooves are perforations and the number of perforations in the third disk member and the number of spinneret orifices in the orifice block satisfy the equations:

wherein the symbols Di, Dm and D0 respectively represent the number of the perforations in the innermost annular groove, the number of perforations in annular groove No. In counted from the innermost groove and the number of perforations in the outermost annular groove;'Nm is the number of the orifices arranged along the concen tric circumference No. m as counted from the innermost circumference; k is a constant; V is a coeflicient ranging from 0.8 to 1.2 and more preferably from 0.93 to 1.07.

4. A spinneret device as set forth in claim 3, wherein the perforations have a diameter satisfying the equation:

wherein the symbol D111 is as defined in claim 3; Rm is the diameter of the perforations; k is a constant; and a represents a power ranging from 3.6 to 4.2 and more preferably from 3.8 to 4.0.

5. A spinneret device as set forth in claim 1, wherein said concentric annular partition means have a concave cross-section at the extremity surface whereby turbulence is produced in said spinning dopes as said dopes flow from adjacent grooves to intermediate spinning orifices and conjugatability of said spinning dopes is improved.

6. A spinneret device as set forth in claim 3, wherein the length and diameter of perforations in the third disk member satisfy the equation:

wherein R is the diameter of the perforations; d is the length of the perforations; k" is a constant and V is as defined in claim 3.

7. A spinneret device as set forth in claim 3 wherein the length and diameter of perforations in the second disk member satisfy the equation:

R=k"dV wherein R is the diameter of the perforations; d is the length of the perforations; k" is a constant and V is as defined in claim 3.

Gleferences on following page) 9 10 References Cited 3,006,028 10/ 1961 Calhoun 188 UNITED STATES PATENTS 3,121,254 2/1964 Heynen et a1. 18-8 2, 6,173 10/1945 Kulp et a1, 18--8 ,237,245 3/1966 Nonarni et a1. 18--8 2,440,761 5/1948 Sisson et a1. 18-8 2,988,420 6/1961 Ryan et a1, 5 WILLIAM J. STEPHENSON, Primary Examiner. 

1. IN A SPINNERET DEVICE FOR USE IN SPINNING A PLURALITY OF SIDE-BY-SIDE COMPOSITE FIBERS, THE COMBINATION INCLUDING AN INTRODUCTION BLOCK HAVING FIRST AND SECOND LONGITUDINAL PASSAGES FOR SUPPLYING RESPECTIVELY FIRST AND SECOND SPINNING DOPES, AN ANNULAR RECESS IN THE SURFACE OF SAID INTRODUCTION BLOCK COMMUNICATING WITH THE SECOND LONGITUDINAL PASSAGE, A DISTRIBUTION BLOCK ADJACENT SAID INTRODUCTION BLOCK COMPRISING A FIRST DISC MEMBER HAVING MEANS DEFINING A CENTAL OPENING COMMUNICATING WITH THE FIRST LONGITUDINAL PASSAGE, A PLURALITY OF RADIALLY EXTENDED RECESES IN THE UNDER SURFACE OF SAID FIRST DISC MEMBER, EACH OF SAID RADIALLY EXTENDED RECESSES COMMUNICATING WITH SAID MEANS DEFINING A CENTRAL OPENING SO AS TO DISTRIBUTE SAID FIRST SPINNING DOPE IN A RADIAL DIRECTION, MEANS DEFINING A PLURALITY OF RADIALLY EXTENDED OPENINGS IN SAID FIRST DISC MEMBER ARRANGED ALTERNATELY BETWEEN SAID RECESSES AND COMMUNICATING WITH SAID ANNULAR RECESS, A SECOND DISC MEMBER HAVING A PLURALITY OF PERFORATIONS BEING ARRANGED ALONG A PLURALITY OF CONCENTRIC CIRCUMGERENCES SUCH THAT PERFORATIONS ALONG ALTERNATE CONCENTRIC CIRCUMFERENCES COMMUNICATE WITH SAID MEANS DEFINING RADIALLY EXTENDED OPENINGS WHILE THE PERFORATIONS ALONG THE OTHER CONCENTRIC CIRCUMFERENCES COMMUNICATE WITH SAID RADIALLY EXTENDED RECESSES, A THIRD DISC MEMBER HAVING A PLURALITY OF CONCENTRIC ANNULAR GOOVES CORRESPONDINGLY LOCATED IN THE UPPER AND LOWER SURFACES THEREOF, MEANS CONNECTING SAID GROOVES IN THE UPPER SURFACE WITH CORRESPONDINGLY LOCATED GROOVES IN THE LOWER SURFACE, 